Electrical connector

Abstract

An electrical connector includes an outer shell having a first passageway therethrough, an inner housing mounted within the first passageway and having a second passageway therethrough and a terminal module mounted within the second passageway. The terminal module includes first and second inserts, a plurality of first terminals extending through the first insert, a plurality of second terminals extending through the second insert, a first seal between the first and second inserts and engaged thereagainst, and a second separate seal extending around an outer perimeter of the first and second inserts and the first seal. The second seal is engaged against the first and second inserts, the first seal and the inner housing. A method of forming the connector is also provided.

Description

ELECTRICAL CONNECTORTECHNICAL FIELD

[0001] This disclosure relates to an electrical connector having a plurality of terminals coupled with a circuit board, and which are potted by a potting material into place.DESCRIPTION OF RELATED ART

[0002] Electrical connectors use a potting material to pot terminals and circuit boards into a housing to hold the components in place. Since the potting material is thin and viscous, it is desirable to control where the potting material flows during the injection to prevent the potting material from flowing into parts of the connector where the potting material is not desired.

[0003] The description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity.SUMMARY

[0004] In an embodiment, an electrical connector includes an outer shell having a first passageway therethrough, an inner housing mounted within the first passageway and having a second passageway therethrough and a terminal module mounted within the second passageway. The terminal module includes first and second inserts, a plurality of first terminals extending through the first insert, a plurality of second terminals extending through the second insert, a first seal between the first and second inserts and engaged thereagainst, and a second separate seal extending around an outer perimeter of the first and second inserts and the first seal. The second seal is engaged against the first and second inserts, the first seal and the inner housing.

[0005] In an embodiment, the second passageway includes a first socket extending from a first end of the inner housing to an intermediate wall of the inner housing, a second socket extending from a second end of the inner housing to the intermediate wall, and a plurality of spaced apart openings extending through the intermediate wall. The first and second inserts and the first and second seals seat within the first socket, and the terminals extend through the openings in the intermediate wall and into the second socket.

[0006] In an embodiment, a potting material is injected into the second socket. A circuit board is coupled to the terminals within the second socket prior to injection of the potting material.

[0007] In an embodiment, the inner housing has a plurality of first and second sockets.

[0008] The inserts may be mechanically coupled together. The inserts may include mounting legs and openings, and the mounting legs seat within the openings to couple to the inserts together. The mounting legs extend through the first seal.

[0009] The second seal is a continuous ring extending around the outer perimeter of the inserts and the first seal. Each insert has a slot in it outer perimeter, and the first seal has a pair of cutouts which align with the slots. The second seal seats within the slots and cutouts.

[0010] In an embodiment, the inserts are hermaphroditic.

[0011] In an embodiment, the terminals are in a preloaded condition in the inner housing.

[0012] A method of assembling the electrical connector with a circuit board is also provided. The terminal module is inserted into the second passageway of the inner housing thereby compressing the second seal between the inserts and the inner housing, and thereafter a potting material is injected into the second passageway. In an embodiment, the second passageway includes a first socket extending from a first end of the inner housing to an intermediate wall of the inner housing, a second socket extending from a second end of the inner housing to the intermediate wall, and a plurality of spaced apart openings extending through the intermediate wall, wherein the terminal module is inserted into the second passageway such that the first and second inserts and the first and second seals seat within the first socket, and the terminals extend through the openings in the intermediate wall and into the second socket, and wherein the potting material is injected into the second socket. The terminals are placed in a pre-load condition upon insertion of the terminal module into the inner housing.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present application is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:

[0014] FIG. 1 depicts a perspective view of an electrical plug connector in accordance with an embodiment of the present disclosure and a mating receptacle connector;

[0015] FIGS. 2 and 3 depict front and rear perspective views of an inner housing and terminal module of the electrical plug connector;

[0016] FIG. 4 depicts an exploded perspective view of the inner housing and terminal module;

[0017] FIG. 5 depicts a perspective view of the terminal module;

[0018] FIG. 6 depicts a bottom plan view of an insert of the terminal module;

[0019] FIG. 7 depicts a perspective view of seals of the terminal module;

[0020] FIG. 8 depicts a cross-sectional view of the terminal module;

[0021] FIG. 9 depicts a first end view of the inner housing of the electrical plug connector;

[0022] FIG. 10 depicts a first end view of the terminal module;

[0023] FIG. 11 depicts a second end view of the inner housing of the electrical plug connector;

[0024] FIG. 12 depicts a second end view of the terminal module;

[0025] FIG. 13 depicts a cross-sectional view of the terminal module within the inner housing, and having a blade inserted therein;

[0026] FIG. 14 depicts a cross-sectional view of the terminal module within the inner housing, and having circuit boards inserted therein; and

[0027] FIG. 15 depicts a perspective view of an alternate inner housing and circuit board. DETAILED DESCRIPTION

[0028] While the disclosure may be susceptible to embodiments in different forms, it is shown in the drawings and herein which is described in detail, specific embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure and is not intended to limit the disclosure to that as illustrated and described herein. Therefore, unless otherwise noted, features disclosed herein may be combined to form additional combinations that were not otherwise shown for purposes of brevity. It will be further appreciated that in some embodiments, one or more elements illustrated by way of example in a drawing(s) may be eliminated and / or substituted with alternative elements within the scope of the disclosure.

[0029] Directional terms such as front, rear, horizontal, vertical and the like are used for ease in explanation, and do not denote a required orientation in use.

[0030] An electrical plug connector 20, see FIG. 1, is provided for coupling two components together, such as a circuit board 22 mounted to the plug connector 20 with a circuit board 24 mounted within a receptacle connector 26. Each circuit board 22, 24 has a plurality of contact pads 28, 30 thereon. As shown in FIGS. 1-3, the plug connector 20 includes an insulative outer shell 32, an insulative inner housing 34 mounted within a passageway 36 of the outer shell 32, and a terminal module 38 mounted within the inner housing 34. The outer shell 32 may be formed as two parts 32a, 32b which are mated together as shown in FIG. 1.

[0031] As shown in FIGS. 4, 13 and 14, the inner housing 34 has a top wall 40, a bottom wall 42 and side walls 44, 46 extending between opposite side edges of the top and bottom walls 40, 42. A first socket 48 extends in a longitudinal direction from a first end 50 of theinner housing 34 to an intermediate wall 52 that extends between the walls 40, 42, 44, 46, and a second socket 54 extends in the longitudinal direction from a second opposite end 56 of the inner housing 34 to the intermediate wall 52. A row of upper openings 58 extend through the intermediate wall 52 in the longitudinal direction and couple the first and second sockets 48, 54 together, and a row of spaced apart lower openings 60 extend through the intermediate wall 52 in the longitudinal direction and couple the first and second sockets 48, 54 together.

[0032] The first socket 48 is formed from a planartop wall surface 62, an opposite planar bottom wall surface 64, first and second side wall surfaces 66, 68 extending between opposite side edges of the top and bottom wall surfaces 62, 64, and a first planar surface of the intermediate wall 52 forms an end wall surface of the first socket 48. The second socket 54 is formed from a planar top wall surface 70, an opposite planar bottom wall surface 72, first and second side wall surfaces 74, 76 extending between opposite side edges of the top and bottom wall surfaces 70, 72, and a second planar surface of the intermediate wall 52 forms an end wall surface of the second socket 54.

[0033] The openings 58 are vertically aligned with each other, and the openings 60 are vertically aligned with each other. Each opening 58, 60 may be rectangular in cross-section and the walls forming each opening 58, 60 are planar. The upper openings 58 are offset in the horizontal direction from the lower openings 60. The openings 58, 60 may have other cross-sectional shapes. The disclosure is not limited to any particular number of openings 58, 60.

[0034] A plurality of spaced apart elongated upper apertures 78 are provided through the top wall 40 and are open to the second socket 54. A plurality of elongated, longitudinally extending upper slots 80 are provided in the lower surface of the top wall 40 and are open to the second socket 54. Respective ones of the slots 80 extend between the respective ones of the upper opening 58 and respective ones of the upper aperture 78.

[0035] Each upper slot 80 extends in the longitudinal direction. Each upper slot 80 is formed from a top wall surface 82 which extends longitudinally from a top wall surface of the upper opening 58, and first and second side parallel and spaced apart wall surfaces 84 extending downward between opposite ends of the top wall surface 82 and extending longitudinally from a side wall surfaces of the upper opening 58. Each upper slot 80 may be rectangular in the longitudinal and lateral cross-sections and the wall surfaces forming the slots 80 are planar.

[0036] Each elongated upper aperture 78 extends in the longitudinal direction. Each upper aperture 78 is formed from a first wall surface 86 which is proximate to, but spaced from the intermediate wall 52, a second wall surface 88 which is proximate to, but spaced from, the second end 56, first and second side parallel and spaced apart wall surfaces 90 extending between opposite side edges of the first and second wall surfaces 88, and a lower wall surface 92 which extends a predetermined distance toward the intermediate wall 52. The lower wall surfaces 92 are formed by projections 94 of the top wall 40 which extend into the respective elongated upper aperture 78. The projections 94 are formed by the wall surface 92, an opposite lower wall surface 96 and an end surface 98 which faces the intermediate wall 52. The lower wall surface 96 is vertically below the top surface of the respective upper slot 80, and the lower wall surface 96 is vertically above the bottom wall surface of the opening 58. As a result, a pocket 100 is formed as part of each upper aperture 78 above the lower wall surface 88.

[0037] A plurality of spaced apart elongated lower apertures (not shown) are provided through the bottom wall 42 and are open to the second socket 54 and include a pocket 104. The lower apertures and pockets 104 are identically formed to the upper apertures 78 and pockets 100 except that the lower apertures (not shown) are provided through the bottom wall 42 and the pockets 104 are formed in the bottom wall 42. A plurality of elongated, longitudinally extending lower slots 102 are provided in the upper surface of the bottom wall 42 and are open to the second socket 54. The lower slots 102 are identically formed to the upper slots 80 except that the lower slots 102 are provided through the bottom wall 42. Therefore, the specifics are not repeated herein.

[0038] The socket 48, the openings 58, 60, the upper and lower slots 80, 102, the upper apertures 78 and the lower apertures (not shown), and the pockets 100, 104 form a passageway through the inner housing 34.

[0039] As shown in FIGS. 4-8, 10 and 12, the terminal module 38 includes first and second insulative inserts 120, 120’, first and second separate seals 122, 124, and first and second rows of spaced apart conductive terminals 126, 126’. The first seal 122 seats between the first and second inserts 120, 120’. The second seal 124 extends around an outer perimeter of the first and second inserts 120, 120’ and the first seal 122. The terminals 126

[0040] The first and second inserts 120, 120’ are formed of a rigid material. In an embodiment, the inserts 120, 120’ are hermaphroditic so only insert 120 is described with the understanding that insert 120’ shows like components with a prime after the reference numeral. The inserts 120, 120’ may be formed from liquid crystal polymer material.

[0041] As shown, the insert 120 is formed generally as a rectangular prism, formed by opposite upper and lower surfaces 128, 130, first and second end surfaces 132, 134 extending between the upper and lower surfaces 128, 130, and opposite side surfaces 136, 138 at the ends thereof. A length of the insert 120, which is defined between end surfaces 132, 134 and which extends in the longitudinal direction along the side surfaces 138, 140, is short. An elongated continuous slot 142 has a top section 144 that extends along the width of the upper surface 128 at the midpoint thereof, a side section 146 that extends along the side surface 136 along its height at the midpoint thereof, and a third section 148 that extends along the side surface 138 along its height at the midpoint thereof. The sections 144, 146, 148 are aligned with each other in the longitudinal direction. A row of spaced apart passageways 150 extend through the insert 120 from the surface 132 to the surface 134.

[0042] A plurality of spaced apart mounting legs 152, see FIG. 6, extend from the surface 130 and a plurality of spaced apart mounting apertures 154 extend into the surface 130, but do not intersect the passageways 150. The mounting legs 152 of the first insert 120 seat within the mounting apertures 154’ in the second insert 120’, and the mounting legs 152’ of the second insert 120’ seat within the mounting apertures 154 in the first insert 120 to mechanically couple the inserts 120, 120’ together. The mounting legs 152, 152’ and mounting apertures 154, 154’ may have different shapes to provide a friction fit. The mounting legs 152 are longer than the mounting apertures 154 such that a gap is provided between the surfaces 130, 130’ when the inserts 120, 120’ are mated together. The passageways 150 in the insert 120 are offset from the passageways 150’ in the insert 120’. A pair of mounting ears 156 may extend from the surface 132 for coupling to a mating structure in the inner housing 34.

[0043] While the inserts 120, 120’ are shown as generally rectangular prisms, the inserts 120, 120’ can be square prisms or other suitable shapes. Also, while the inserts 120, 120’ are described as being hermaphroditic, the inserts 120, 120’ are not required to be hermaphroditic.

[0044] The first seal 122 seats within and fills the gap between the inserts 120, 120’. The first seal 122 may be formed of an elastomeric material, and may be formed of silicone. As shown, the first seal 122 is formed generally as a rectangular prism, formed by opposite top and bottom surfaces 158, 160 which conform in shape to the surfaces 130, 130’ of the inserts 120, 120’ and wall surfaces 162, 164, 166, 168 extending therebetween. The surface 158 engages against the surface 130 of the insert 120, and the surface 160 engages against the surface 130’ of the insert 120’ to fill the gap therebetween. A cutout 170, 172 is provided inthe surfaces 166, 168 and the cutouts 170, 172 align longitudinally with each other and align with the sections 146, 148, 146’, 148’ of the slots 142, 142’.

[0045] The second seal 124 extends around and contacts the outer perimeter defined by the inserts 120, 120’ and the first seal 122. The second seal 124 is formed as a continuous ring, seats within and fills the slot 142, the cutout 170, the slot 142’ and the cutout 172. The second seal 124 may be formed of an elastomeric material, and may be formed of silicone.

[0046] The terminals 126, 126’ may be formed of gold plated copper alloy. The terminals 126 pass through the passageways 150 in the insert 120, and the terminals 126’ pass through the passageways 150’ in the insert 120’. Each terminal 126, 126’ is identically formed so a single terminal 126 is described with the understanding that the other terminals have like elements denoted by like reference numerals and the terminals 126’ include a prime after the reference numeral.

[0047] As best shown in FIGS. 8, 13 and 14, the terminal 126 has a planar central section 174 which is seated within the passageway 150 and extends a predetermined distance outwardly from the surfaces 132, 134, a first deflectable leg 176 extending from the central section 174 and from the surface 132 of the insert 120, and a second deflectable leg 178 extending from the central section 174 and from the surface 134 of the insert 120. The first deflectable leg 176 has a first section 180 which extends from an end of the central section 174 at an angle, a second section 182 which extends from the end of the first section 180 at an angle, a third generally U-shaped section 184 which extends from the end of the second section 182, and a fourth section 186 which extends from the end of the third section 184 and is generally parallel to the central section 174. In an unloaded condition, the second deflectable leg 178 has a first section 188 which extends from an end of the central section 174 at an angle, a second generally U-shaped section 190 which extends from the end of the first section 188, and a third section 192 which extends from the end of the second section 190 and is generally parallel to the central section 174.

[0048] The first sections 180, 180’ angle outward from each other, the second sections 182, 182 angle inward toward each other, the third sections 184, 184’ are close to each other and define a gap 194 therebetween, and the fourth sections 186, 186’ are spaced apart from each other a distance which is greater than the gap 194. The first sections 188, 188’ angle inward toward each other, the second sections 184, 184’ overlap each other vertically, and the fourth sections 186, 186’ are spaced apart from each other.

[0049] The terminals 126, 126’ may be coupled to the respective inserts 120, 120’ by insert molding.

[0050] The terminal module 38 is seated within the inner housing 34. The passageways 150 in the insert 120 align with respective ones of the upper openings 58 through the intermediate wall 52 of the inner housing 34, and the passageways 150’ in the insert 120’ align with respective ones of the lower openings 60 through the intermediate wall 52. Prior to insertion of the terminal module 38 into the inner housing 34, a blade 196, see FIG. 13, is inserted into the second socket 54 which has an end having angled surfaces 198, 200.

[0051] The terminal module 38 is then inserted into the inner housing 34 by first passing the second deflectable legs 178, 178’ into the first socket 48, then through the openings 58, 60 in the intermediate wall 52, then through the respective upper and lower slots 80, 102, until the second generally U-shaped sections 190, 190’ engage with the angled surfaces 198, 200 of the blade 196. The second deflectable legs 178, 178’ deflect as they pass through the openings 58, 60 in the intermediate wall 52; each opening 58, 60 has a height which allows for the deflected legs 178, 178’ to pass through. The slots 80, 102 and the second socket 54 define a height which is greater than the height of each pair of second deflectable legs 178, 178’ to allow movement of the second deflectable legs 178, 178’ therein. The engagement with the blade 196 causes the second deflectable legs 178, 178’ to deflect outward and to move the third sections 192, 192’ further into the upper and lower openings and then into the respective pockets 100, 104. A space 202 is then formed between the second generally U- shaped sections 190, 190’. The slots 80, 102 and the second socket 54 define a height which is greater than the height of each pair of second deflectable legs 178, 178’ to allow movement of the second deflectable legs 178, 178’ therein. After passing into the apertures 78 (and the apertures in the bottom wall 42), the second deflectable legs 178, 178’ relax and the third sections 192, 192’ rest against the wall surfaces 88 (and the like wall surfaces for the lower openings). This effects a preload on the second deflectable legs 178, 178’ prior to engagement of the second deflectable legs 178, 178’ with the circuit board 22 such that the terminals 126, 126’ are in a preload condition. The inserts 120, 120’ engage against the first planar surface of the intermediate wall 52, and the second seal 124 engages against and compresses between the inserts 120, 120’ and the wall surfaces 62, 64, 66, 68 of the socket 48 to form a watertight seal therebetween. The seals 122, 124 deter the passage of moisture between the sockets 48, 54. The deflectable legs 176, 176’ extend partially out of the socket 48. After insertion of the terminal module 38 into the inner housing 34, the blade 196 is removed from the socket 54.

[0052] After the inner housing 34 and terminal module 38 are seated within the outer shell 32, the circuit boards 22, 24 are inserted and engaged with the legs 176, 176’, 178, 178’, seeFIG. 14, the legs 176, 176’, 178, 178’ and contact pads 28, 30 are soldered together, and thereafter the assembly is inserted into the passageway 36 of the outer shell 32 and the sockets 48, 54 are continuous with the passageway 36.

[0053] The first socket 48 has a height between its top and bottom wall surfaces 62, 64 which is greater than the height of each pair of first legs 176, 176’ which is defined as the distance between the joint between the first and second sections 180, 182 and the joint between the first and second sections 180’, 182’. As a result, when the circuit board 24 is inserted into the socket 48, the circuit board 24 first passes into the gap 194 which causes the first legs 176, 176’ to deflect outwardly toward the wall surfaces 62, 64. The third generally U-shaped section 184, 184’ engage against the contact pads 30 on the circuit board 24.

[0054] The socket 54, slots 80, 102 and upper and lower openings define heights which are greater than the height of each pair of second legs 178, 178’. As a result, when the circuit board 22 is inserted into the socket 54, the circuit board 22 passes into the space 202 which causes the legs 178, 178’ to deflect outwardly away from the walls 88 of the pockets 100, 104 as shown in FIG. 14. The second generally U-shaped sections 190, 190’ engage against the contact pads 28 on the circuit board 22. The preload on the legs 178, 178’ assist in the insertion of the circuit board 22 into the terminal module 38 and increase the number of cycles that the plug connector 20 is capable of performing.

[0055] After the circuit boards 22, 24 are assembled with and are soldered to the terminals 126, 126’, a thin, viscous potting material 204, see FIG. 1, is injected into the passageway 36 of the outer shell 32 and into the socket 54 of the terminal module 38. The seals 122, 124 deter the passage of the potting material 204 from the socket 54 and into the socket 48.

[0056] In addition, while pre loaded terminals 126, 126’ are disclosed herein, other forms of terminals, such as straight pins, non-loaded terminals, coaxial cables, etc., can instead be provided, or can be additionally provided through the inserts 120, 120’; the seals 122, 124 function to waterproof the terminal module 38 within the inner housing 34 and prevent the potting material 204 from passing into the socket 54. While a single row of upper terminals 126 and a single row of lower terminals 126’ are shown and described in the plug connector 20, multiple terminal modules 38 (with the described preloaded terminals 126, 126’ and / or other terminals) can be provided within a common housing in the plug connector.

[0057] FIG. 15 illustrates another embodiment of an inner housing 232 which can be provided within the outer shell 12 and coupled to another embodiment of a circuit board 222 having groups of contact pads 228 thereon. The inner housing 232 has a plurality of sockets 248, each formed identical to socket 48, each of which extends in a longitudinal directionfrom a first end 250 of the inner housing 234 to an intermediate wall (not shown, but identical to intermediate wall 52) and from which a second socket (not shown, but identical to second socket 54). Each socket 248 has openings 278 (like apertures 78) and may have slots and pockets like the embodiment shown in FIGS. 2-14. The circuit board 222 has slots 306 into which a wall portion 308 provided between the individual sockets 248 seats.

[0058] The use of the terms “a” and “an” and “the” and “at least one” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0059] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

CLAIMS1. An electrical connector comprising: an outer shell having a first passageway therethrough; an inner housing mounted within the first passageway, the inner housing having a second passageway therethrough; and a terminal module mounted within the second passageway, the terminal module including first and second inserts, a plurality of first terminals extending through the first insert, a plurality of second terminals extending through the second insert, a first seal between the first and second inserts and engaged thereagainst, and a second separate seal extending around an outer perimeter of the first and second inserts and the first seal, and the second seal being engaged against the first and second inserts, the first seal and the inner housing.

2. The electrical connector of claim 1, wherein the second passageway comprises a first socket extending from a first end of the inner housing to an intermediate wall of the inner housing, a second socket extending from a second end of the inner housing to the intermediate wall, and a plurality of spaced apart openings extending through the intermediate wall, wherein the first and second inserts and the first and second seals seat within the first socket, and the terminals further extend through the openings in the intermediate wall and into the second socket.

3. The electrical connector of claim 2, further comprising a potting material within the second socket.

4. The electrical connector of claim 2, further comprising a circuit board coupled to the terminals within the second socket, and further comprising a potting material within the second socket.

5. The electrical connector of claim 2, wherein a plurality of first and second sockets are provided in the inner housing.

6. The electrical connector of claim 1, further comprising a potting material within the second passageway.

7. The electrical connector of claim 1, further comprising a circuit board coupled to the terminals within the second passageway, and further comprising a potting material within the second passageway.

8. The electrical connector of claim 1, wherein the inserts are mechanically coupled together.

9. The electrical connector of claim 1, wherein the inserts include mounting legs and openings, wherein the mounting legs seat within the openings to couple to the inserts together.

10. The electrical connector of claim 9, wherein the mounting legs extend through the first seal.

11. The electrical connector of claim 1, wherein each seal is formed of elastomeric material.

12. The electrical connector of claim 1, wherein each seal is formed of silicone.

13. The electrical connector of claim 1, wherein each insert is a rectangular prism, and the first seal is a rectangular prism, wherein the second seal is a ring extending around the outer perimeter.

14. The electrical connector of claim 1, wherein the second seal is a continuous ring extending around the outer perimeter.

15. The electrical connector of claim 1, wherein each insert has a slot in it outer perimeter, and the first seal has a pair of cutouts which align with the slots, and wherein the second seal seats within the slots and cutouts.

16. The electrical connector of claim 1, wherein the inserts are hermaphroditic.

17. The electrical connector of claim 1, wherein the first and second terminals are in a preloaded condition in the inner housing.

18. A method of assembling an electrical connector with a circuit board comprising: providing an outer shell having a first passageway therethrough; providing an inner housing having a second passageway therethrough; providing a terminal module including first and second inserts, a plurality of first terminals extending through the first insert, a plurality of second terminals extending through the second insert, a first seal between the first and second inserts and engaged thereagainst, and a second separate seal extending around an outer perimeter of the first and second inserts and the first seal, and the second seal being engaged against the first and second inserts, the first seal and the inner housing; inserting the terminal module into the second passageway of the inner housing thereby compressing the second seal between the inserts and the inner housing; and injecting a potting material into the second passageway.

19. The method of claim 18, wherein the second passageway comprises a first socket extending from a first end of the inner housing to an intermediate wall of the inner housing, a second socket extending from a second end of the inner housing to the intermediate wall, and a plurality of spaced apart openings extending through the intermediate wall, wherein the terminal module is inserted into the second passageway such that the first and second inserts and the first and second seals seat within the first socket, and the terminals extend through the openings in the intermediate wall and into the second socket, and wherein the potting material is injected into the second socket.

20. The method of claim 18, wherein the terminals are placed in a pre-load condition upon insertion of the terminal module into the inner housing.

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